US5188981A - Molded article with integral heat shield - Google Patents

Molded article with integral heat shield Download PDF

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Publication number
US5188981A
US5188981A US07/706,605 US70660591A US5188981A US 5188981 A US5188981 A US 5188981A US 70660591 A US70660591 A US 70660591A US 5188981 A US5188981 A US 5188981A
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United States
Prior art keywords
heat
molded article
heat shield
molded
insulating material
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Expired - Lifetime
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US07/706,605
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English (en)
Inventor
Ernest D. Stiles
Ronald K. Wlosinski
Daniel Q. Houston
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Ford Global Technologies LLC
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Ford Motor Co
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Priority to US07/706,605 priority Critical patent/US5188981A/en
Assigned to FORD MOTOR COMPANY A CORPORATION OF DE reassignment FORD MOTOR COMPANY A CORPORATION OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: HOUSTON, DANIEL Q., STILES, ERNEST D., WLOSINSKI, RONALD K.
Priority to DE69205065T priority patent/DE69205065T2/de
Priority to EP19920303924 priority patent/EP0516290B1/fr
Priority to US07/952,374 priority patent/US5308571A/en
Application granted granted Critical
Publication of US5188981A publication Critical patent/US5188981A/en
Assigned to FORD GLOBAL TECHNOLOGIES, INC. A MICHIGAN CORPORATION reassignment FORD GLOBAL TECHNOLOGIES, INC. A MICHIGAN CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FORD MOTOR COMPANY, A DELAWARE CORPORATION
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K15/03177—Fuel tanks made of non-metallic material, e.g. plastics, or of a combination of non-metallic and metallic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2017—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements outside the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0016—Non-flammable or resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/003—Reflective
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7172—Fuel tanks, jerry cans
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K2015/03032—Manufacturing of fuel tanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K2015/03328—Arrangements or special measures related to fuel tanks or fuel handling
    • B60K2015/03421—Arrangements or special measures related to fuel tanks or fuel handling to protect the fuel tank against heat
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/913—Material designed to be responsive to temperature, light, moisture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/24996—With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof

Definitions

  • This invention relates to a molded article having an integral heat shield and a method of making the same.
  • Molded articles are useful in a variety of applications. Molded articles include both thermoset composite and thermoplastic material. Thermoset composite materials are made by combining a fiber reinforcement with a liquid resin. The resin wets the fiber reinforcement material and then cures. Thermoplastic material is thermoformable and may be injection molded or blow-molded to form articles having very complex shapes. Blow-molding is especially useful for manufacturing articles for holding fluids such as containers.
  • Both types of molded articles are generally sensitive to exposure at elevated temperatures.
  • Thermoplastic and thermoset composite articles tend to soften when exposed to temperatures above their melting point.
  • Thermoset composite articles tend to oxidize the resin portion of the composite material.
  • the molded article becomes structurally weakened by the exposure to elevated temperatures. When localized areas are exposed to elevated temperature, these localized areas tend to weaken.
  • the exposure of the molded article to elevated temperature is localized. Manufacturing an entire molded article with these high temperature resistant materials is unnecessary. It is one object of the present invention to provide an integral heat shield for protecting localized areas of molded articles from elevated temperatures. It is a further object of the present invention to provide a low cost method of fabricating a molded article with an integral heat shield. It is a further object of the present invention to provide a lightweight molded article having and integral heat shield to protect localized areas from elevated temperatures.
  • the present invention relates to a molded article comprising a preformed body and one or more layers of heat shielding material attached to the preform body.
  • the heat shielding material is placed on localized areas of the molded article which are exposed to elevated temperatures.
  • the molded article may be a fiber reinforced plastic (FRP) which comprises a fibrous material containing a resin or alternatively, the molded article may be a thermoplastic material with or without reinforcement.
  • FRP fiber reinforced plastic
  • the invention also provides a method of making a FRP molded article having an integrally molded heat shield comprising the steps of providing a preform, placing one or more layers of heat shielding material adjacent to the preform and injecting resin in the preform to form a molded article.
  • a thermoformable article having an integrally molded heat shield may be made by the steps of providing a thermoformable article, placing one or more layers of heat shielding material adjacent the preform and attaching a heat shielding material to the preform.
  • the heat shielding material may comprise one or more layers of heat insulating material and/or one or more layers of heat reflecting material.
  • Various types of heat insulating material made from ceramic fiber and silicone foam material can be used in the present invention.
  • ceramic materials useful in the present invention preferred are those made of silica.
  • the ceramic fiber material may be made in a woven, braided, wound, chopped, looped, or structurally engineered fashion.
  • the foam material may be made with either open or closed celled as will be described in more detail.
  • the fiber and open cell foam material is porous and permits resin to wet the material.
  • the closed cell or very tightly woven material is non-porous and does not permit resin to significantly wet the insulation material. Wetting as used herein is the impregnation of resin within a material.
  • the insulating material may be used alone or in combination with a heat reflecting material.
  • the heat reflecting material is generally an infrared reflecting material such as a metal foil.
  • the heat reflecting material may be partially foraminous to assist in adhering to the molded article.
  • the heat reflecting material may be used with or without insulating material.
  • the heat reflecting material acts to reflect heat away from the molded article whereas the heat insulating material acts to reduce the amount of heat which reaches the molded article.
  • Both the insulating and reflecting material act to shield the molded article from the damaging effects of elevated temperatures.
  • the invention integrates the heat shield within the molded article to insure the heat shield is correctly positioned and to protect the heat shield from being damaged or removed. Integrating the heat shield within the molded article also reduces manufacturing and assembly costs as well as the bulk and weight of article and heat shield.
  • FIG. 1 shows an exploded view of a preform and heat shield in a mold.
  • FIG. 2 shows a sectional view along the line II--II in FIG. 1 with the mold in the closed position.
  • FIG. 3 is a detail cross-sectional view along the line III--III in FIG. 2 showing the final molded article removed from the mold.
  • FIG. 4 is an edge view of a finished molded article placed adjacent a heat source.
  • FIGS. 6-9 diagrammatically show the manufacture of a blow-molded article incorporating an integrated heat shield.
  • FIGS. 1-3 show the manufacture of an integrally molded heat shield on a thermoset composite crossmember 8 for an automobile.
  • a preform 10 generally conforming to the desired shape of the crossmember is placed in a mold.
  • Preform 10 may be made by a variety of conventional methods. It may contain a foam core, blow-molded core, metal reinforced core, or maybe a hollow. Shown in FIG. 1 is preform 10 having a foam core 13 surrounded by fibrous mat 14.
  • Foam core 13 and fibrous mat 14 may be made from a wide variety of materials which are well known in the FRP art. Specifically preferred for foam core 13 are closed cell urethane materials. Fibrous mat 14 maybe fibrous material having a continuous strand or directional fiber placement.
  • Preform 10 is made generally in the shape of the final molded article and has a localized area 16 for receiving a heat shielding material.
  • Localized area 16 may be dish-shaped to receive the heat shielding material. Providing a dish-shape to localized area 16, permits the finished crossmember 8 to have a smooth exterior finish. If a smooth exterior finish is not required, localized area 16 may be flush with the surface of preform 10 so that the heat shield extends above the surface of the crossmember 8.
  • Heat shield 12 is attached to preform 10 adjacent localized area 16. Heat shield 12 may be attached to preform 10 by a variety of method including adhesive, compression fit, fasteners, and sewing. Heat shield 12 may optionally be attached to preform 10 in the molding process described below. In this case, heat shield 12 is placed in a mold and preform 10 is placed adjacent heat shield 12 so that localized area 16 registers with heat shield 12.
  • Heat shield 12 may comprise a heat insulating material and/or a heat reflecting material. Shown in FIG. 3 is heat shield 12 comprising two layers of heat insulating material 22,24 and a layer of heat reflecting material 26.
  • Heat insulating material 22 is of porous construction such as a fibrous or open-cell insulating material. Shown is insulating material 22 made of a silica woven insulating material of the type manufactured under the name Thermotec ExoblocTM by Bisco Products. The Thermotec product combines the porous and non-porous insulating materials into one integral product. Both materials are also available alone and in combination with other materials. Other types of suitable porous insulating materials are commercial available such as silicone foam materials from General Electric, and COHlasticTM silicone foam from CHR Industries. A wetting agent may be added to insulating material 22, to aid in wetting insulating material 22 with resin.
  • Non-porous insulating material 24 is attached to insulating material 22.
  • Non-porous insulating material 24 is designed to prevent a liquid resin from passing therethrough.
  • a variety of commercially available heat insulating materials combining the woven and closed-cell construction are commercially available. As stated, the Thermotec product combines both the porous material 22 and non-porous material 24 into one product.
  • a wet-out agent may be added to insulating material 24 to prevent the wetting of insulating material 24 by resin.
  • Woven ceramic fibers offer a very high temperature protection between 1000°-2000° F. Silicone foam products can be used for temperature between 400°-700° F. The woven and foam products can be combined in one or more layers as is necessary to protect the molded article from temperature damage.
  • Heat reflecting material 26 is attached to insulating material 24.
  • Reflecting material 26 may be a metal or metalized foil which is capable of reflecting heat. Suitable materials infrared reflecting materials include aluminum or copper foil having a thickness of between 1-2 mils.
  • Reflecting material 26 may be affixed to insulating material 22 prior to molding. Alternatively, reflecting material 26 may be placed atop insulating material 22 and adhered directly thereto by the molding process. Various layers of insulating and reflecting materials may be combined to provide the heat shielding required for a particular application. It is preferable that the outer layer of crossmember 8 be made of a heat reflecting material to most efficiently reflect infrared heat radiating on the molded article and to help protect the insulating materials beneath from damage.
  • Crossmember 8 is manufactured by a liquid molding process as is well known in the FRP art.
  • Preform 10 and heat shield 12 are placed in a liquid resin injection molding tool 30.
  • Tool 30 comprises first and second die piece 32,34.
  • Die pieces 32,34 have resin channels 36 which communicate a source of pressurized resin (not shown) with the surface of preform 10. Die pieces 32,34 are closed and closely follow the surface of preform 10.
  • Liquid resin 38 is injected through resin channels 36.
  • Resin 38 wets fibrous mat 14.
  • Resin 38 also wets porous insulting material 22.
  • Non-porous insulting material 24 and heat reflecting material 26 are impermeable to liquid resin.
  • Resin 38 does not wet heat shield 12 beyond insulting material 22.
  • Resin 38 is allowed to cure. Once cured, tool 30 is opened and finished crossmember 8 is removed.
  • FIG. 4 shows crossmember 8 installed adjacent an exhaust pipe 40.
  • Heat shield 12 is located in the immediate vicinity of exhaust pipe 40 and protects crossmember 8 from the damaging affects of exposure to high temperatures.
  • heat shield 12 is heated by radiant and convection heating.
  • Reflecting material 26 acts to reflect heat back toward exhaust pipe 40. Heat which is not reflected by reflecting material 26 passes through to non-porous insulating material 24. Insulating material 24 reduces the amount of heat which is transferred to porous insulating material 22.
  • Insulating material 22 acts both as an insulating material and as an attaching mechanism between heat shield 12 and preform 10.
  • Heat shield 12 is designed such that the temperature within insulating material 22 remains well below the glass transition temperature (T g ) of the resin. Slight oxidation of the resin within material 22 is permissible without degrading the mechanical properties of preform 10.
  • T g glass transition temperature
  • the invention as described teaches three layers of heat shielding material: a heat reflecting film nearest the heat source, a non-porous insulating material, and a porous material farthest from the heat source.
  • the invention may be practiced with one or any combination of these heat shielding materials and in any arrangement. While not wishing to be bound by the following theory, it is believed that placing the heat reflecting material nearest the heat source produces the largest amount of heat reflection.
  • insulating material 22 includes some resin 38, it is desirable to maintain the temperature in this layer well below the T.sub. ⁇ of the resin. Placing insulating material 22 farthest from the heat source protects resin 38 from damage and maintains the integrity of the heat shield/preform bond.
  • the invention has been described using a combination of woven and closed-cell insulating material.
  • Other configurations of insulating material are possible and are within the scope of the present invention.
  • An open-cell insulating material (one having an open-cell structure which permits internal passages within the insulating material to communicate resin throughout the material) may be used in place of a woven insulating material.
  • a closed-cell insulating material may also be used as a heat shield.
  • a closed-cell material can rely on the adhesive properties of the resin to adhere the heat shield directly to the preform.
  • the heat reflecting material has been shown overlying the heat insulating material. It is possible to overlay the heat reflecting material directly on the preform. As the resin wets the preform, it also wets the interior surface of the heat reflecting material and adhesively bonds the heat reflecting material directly to the preform. When relatively low heat shielding is required for a molded article, the heat reflecting material may be bonded directly to the preform without any insulating material therebetween. Because the heat reflecting material is relatively thin, in the order of 2 mils, this embodiment may be useful for protecting existing molded articles from high temperatures without modifying their tooling.
  • Integrally molded heat shields may also be useful with thermoformable plastic materials.
  • a method and apparatus for producing a thermoformable article having and integral heat shield is illustrated in FIGS. 6-9.
  • a female molding tool 52 having die pieces 54,56 is used for blow-molding fuel tank 50.
  • Die piece 54 has an interior wall surface 58 conforming to the exterior shape of a molded fuel tank 50.
  • Mold piece 54 has a projection 60. Projection 60 registers with localized area 61 of fuel tank 50 which will be exposed to elevated temperatures.
  • Die piece 56 has an interior wall surface 59. Interior wall surfaces 58,59 shape the exterior surface of molded fuel tank 50.
  • Mold tool 52 is operable to open and close die pieces 54,56. Mold 52 is shown in the open position in FIG. 6.
  • Extruder 64 extrudes a hollow tubularly shaped parison 68 for blow-molding.
  • Mandrel 66 is preferably located within extruder 64 and supplies pressurized gas used in the blow-molding process.
  • Extruder 64 and mandrel 66 are the type commonly used for blow-molding.
  • Heat shield 62 is placed to overlie interior wall surface 58 in the region of projection 60. Heat shield 62 may be retained on projection 60 by pins or adhesive or alternatively, heat shield 62 may be formed in a shape which registers with projection 60 and retained thereon by a press fit. Heat shield 62 may be manufactured as described in the embodiments illustrated in FIGS. 1-5. Heat shield 62 may contain a combination of heat reflecting and heat insulating materials. Heat shield 62 may contain insulating material having open and closed cells, woven or braided construction or other surface configurations as previously described and may containing heat reflecting material as previously described. Heat shield 62 is preferably constructed to have a porous or partially porous surface facing the thermoformable article. This porous surface permits the thermoformable material to partially impregnate itself within heat shield 62.
  • Extruder 64 extrudes a tubular parison 68 of thermoformable material. Many materials are known for use in blow-molding but especially preferred are materials containing primarily polypropylene or polyethylene.
  • a length of parison 68 sufficient to completely fill the length of mold 52 is extruded. Parison 68 is sealed at the bottom portion by closing mold 52 as shown in FIG. 7. Closing mold 52 causes die pieces 54 and 56 to move toward one another, pinching the bottom of parison 68 closed.
  • Blow-molding mandrel 66 supplies pressurized gas to parison 68 as shown in FIG. 8. Parison 68 inflates and is forced against heat shield 62. Parison 68 partially permeates the surface of heat shield 62 to form and integral structure.
  • Parison 68 is allowed to cool and mold tool 52 is opened to remove finished blow-molded fuel tank 50.
  • heat shield 62 Located in a localized area 61 is heat shield 62. Localized area 61 is intended to be exposed to elevated temperatures such as those included near an exhaust pipe in the underbody of an automobile.
  • Heat shield 62 acts to reflect heat away from fuel tank 50 and insulate thermoformable material from exposure to elevated temperatures.
  • the invention as described is suitable for use with thermoset composite as well as thermoformable molded articles.
  • Heat shielding material is integrally molded in localized areas which are intended to be exposed to elevated temperatures. Integrally molding a heat shield within a localized area saves space and weight compared to attaching an external heat shield.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Transportation (AREA)
  • Combustion & Propulsion (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
US07/706,605 1991-05-28 1991-05-28 Molded article with integral heat shield Expired - Lifetime US5188981A (en)

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US07/706,605 US5188981A (en) 1991-05-28 1991-05-28 Molded article with integral heat shield
DE69205065T DE69205065T2 (de) 1991-05-28 1992-04-30 Verfahren zum Formen eines Gegenstandes mit integriertem Hitzeschild.
EP19920303924 EP0516290B1 (fr) 1991-05-28 1992-04-30 Procédé pour le moulage d'un objet ayant un bouclier thermique intégré
US07/952,374 US5308571A (en) 1991-05-28 1992-09-28 Method of molding an article with integral heat shield

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US5656353A (en) * 1995-06-27 1997-08-12 Tba Composites, Inc. Laminated heat shield with prongs and method of manufacturing same
US5674603A (en) * 1992-09-28 1997-10-07 Ford Global Technologies, Inc. Molded article with integral heat shield
US5809998A (en) * 1996-08-08 1998-09-22 The United States Of America As Represented By The Secretary Of The Navy Insulation jacket for breathing gas device
US5914082A (en) * 1995-11-30 1999-06-22 Harrison; Donald G. Method and apparatus for molding thermosetting polymers onto substrates
US5928593A (en) * 1995-11-30 1999-07-27 Harrison; Donald G. Method and apparatus for molding thermosetting polymers onto substrates
US5939004A (en) * 1995-11-30 1999-08-17 Harrison; Donald G. Molding thermosetting polymers onto substrates
WO1999044851A1 (fr) 1998-03-04 1999-09-10 Rieter Automotive (International) Ag Reservoir de carburant a ecran thermique integre
US6071370A (en) * 1993-12-27 2000-06-06 Ford Global Technologies, Inc. Fuel tank with integral heat shield
US6139787A (en) * 1996-10-24 2000-10-31 Ubertech Texas, Inc. Method for applying molded silicone design elements onto substrates
US6193914B1 (en) 1995-11-30 2001-02-27 Ubertech Texas, Inc. Molding thermosetting polymers onto substrates
US6241930B1 (en) 1995-11-30 2001-06-05 Ubertech Texas, Inc. Method of constructing a garment with a graphical design thereon
US6268037B1 (en) 1998-10-28 2001-07-31 Acoust-A-Fiber Research And Development, Inc. Heat shield for blow-molded component
US20030215640A1 (en) * 2002-01-29 2003-11-20 Cabot Corporation Heat resistant aerogel insulation composite, aerogel binder composition, and method for preparing same
US20050025952A1 (en) * 2002-05-15 2005-02-03 Cabot Corporation Heat resistant insulation composite, and method for preparing the same
US20070251092A1 (en) * 2004-07-16 2007-11-01 Advanced Fiber Technologies (Aft) Trust Method of Mnaufacturing a Screen Cylinder and a Screen Cylinder
US20110240389A1 (en) * 2010-03-31 2011-10-06 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Fuel tank
US20160009019A1 (en) * 2013-03-05 2016-01-14 Honda Motor Co., Ltd. Blow-molding mold
US9254586B2 (en) 2008-06-11 2016-02-09 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Process for producing a fuel tank with underride protector
JP2016043564A (ja) * 2014-08-22 2016-04-04 株式会社Fts ブロー成形方法
CN105579271A (zh) * 2013-09-25 2016-05-11 本田技研工业株式会社 机动车用燃料箱
WO2016168899A1 (fr) * 2015-04-24 2016-10-27 Carbon Revolution Pty Ltd Procédé de production d'un composite protégé thermiquement
US20170217075A1 (en) * 2014-09-29 2017-08-03 Plastic Omnium Advanced Innovation And Research Method for welding a heat shield during manufacturing of a vehicle component
US10160311B2 (en) 2013-03-29 2018-12-25 Plastic Omnium Advanced Innovation And Research Method for manufacturing a fuel tank or filling pipe and use thereof in a hybrid vehicle
EP3233520B1 (fr) 2014-12-19 2021-02-24 Mubea Carbo Tech GmbH Structure de bouclier thermique pour une roue

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FR2702541B1 (fr) * 1993-03-09 1995-06-16 Europ Propulsion Procede de fabrication d'elements de protection thermique, en particulier pour avions spatiaux.
AU668470B2 (en) * 1993-07-12 1996-05-02 Seaward International, Inc. Elongated structural member and method and apparatus for making same
DE19705511C5 (de) * 1997-02-13 2005-07-14 Faist Automotive Gmbh & Co. Kg Hitzeschild für Bauteile aus thermoplastischem Kunststoff
US5846634A (en) * 1997-03-05 1998-12-08 Pilot Industries, Inc. Heat shield and method of manufacturing the heat shield
US6001437A (en) * 1997-07-17 1999-12-14 Nu-Chem, Inc. Method of making high-temperature glass fiber and thermal protective structures
FR2783196B1 (fr) * 1998-09-15 2000-12-15 Peugeot Procede de fabrication d'une piece en matiere plastique comportant un noyau en mousse, une paroi externe renforcee par des fibres et un element insere
US20070134485A1 (en) * 2005-12-08 2007-06-14 Collins Daniel J Blow molded articles having capped or inserted thermoplastic vulcanizate foam surfaces
DE102017119933A1 (de) * 2017-08-30 2019-02-28 Airbus Operations Gmbh Faserverbundbauteil mit einer Elastomerdichtung sowie ein Verfahren zu dessen Herstellung
EP3666496B1 (fr) * 2018-12-10 2022-04-13 Magna Energy Storage Systems GesmbH Procédé de fabrication d'un réservoir en matière plastique
US11845234B2 (en) 2019-01-25 2023-12-19 National Research Council Of Canada Articulated forming caul for composite blank vacuum forming
DE102019124540A1 (de) * 2019-09-12 2021-03-18 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Herstellen eines flachen Formbauteiles mit einer Faserverbundwerkstofflage und einer metallischen Lage, flaches Formbauteil und Kraftfahrzeug
US11458661B2 (en) * 2019-10-17 2022-10-04 U.S. Farathane Corporation Method for producing a multi shot injection molded article incorporating a heat shield

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US3943676A (en) * 1973-12-24 1976-03-16 Gustav Ickes Modular building wall unit and method for making such unit
US4201829A (en) * 1974-11-29 1980-05-06 The Goodyear Tire & Rubber Company Metal plated thermoplastic articles
US4225109A (en) * 1978-07-06 1980-09-30 Osaka City & Taiyo Manufacturing Works Co., Ltd. Insulated metal mold
US4188463A (en) * 1979-02-01 1980-02-12 Electric Power Research Institute, Inc. Sodium-sulfur battery and method of making a double carbon mat-composite sulfur electrode for use in sodium-sulfur cells
US4426061A (en) * 1980-08-04 1984-01-17 Taggart John R Method and apparatus for forming insulated walls
US4655473A (en) * 1982-06-07 1987-04-07 Realverbund Process of manufacturing a ski
US4849147A (en) * 1985-08-22 1989-07-18 The Budd Company Method of making a molded structure having integrally formed attachment members
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Cited By (34)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5674603A (en) * 1992-09-28 1997-10-07 Ford Global Technologies, Inc. Molded article with integral heat shield
US6071370A (en) * 1993-12-27 2000-06-06 Ford Global Technologies, Inc. Fuel tank with integral heat shield
US5656353A (en) * 1995-06-27 1997-08-12 Tba Composites, Inc. Laminated heat shield with prongs and method of manufacturing same
US6193914B1 (en) 1995-11-30 2001-02-27 Ubertech Texas, Inc. Molding thermosetting polymers onto substrates
US5928593A (en) * 1995-11-30 1999-07-27 Harrison; Donald G. Method and apparatus for molding thermosetting polymers onto substrates
US5939004A (en) * 1995-11-30 1999-08-17 Harrison; Donald G. Molding thermosetting polymers onto substrates
US5914082A (en) * 1995-11-30 1999-06-22 Harrison; Donald G. Method and apparatus for molding thermosetting polymers onto substrates
US6241930B1 (en) 1995-11-30 2001-06-05 Ubertech Texas, Inc. Method of constructing a garment with a graphical design thereon
US5809998A (en) * 1996-08-08 1998-09-22 The United States Of America As Represented By The Secretary Of The Navy Insulation jacket for breathing gas device
US6139787A (en) * 1996-10-24 2000-10-31 Ubertech Texas, Inc. Method for applying molded silicone design elements onto substrates
WO1999044851A1 (fr) 1998-03-04 1999-09-10 Rieter Automotive (International) Ag Reservoir de carburant a ecran thermique integre
US6401961B1 (en) * 1998-03-04 2002-06-11 Rieter Automotive (International) Ag Fuel tank with integrated heat shield
US6268037B1 (en) 1998-10-28 2001-07-31 Acoust-A-Fiber Research And Development, Inc. Heat shield for blow-molded component
US20030215640A1 (en) * 2002-01-29 2003-11-20 Cabot Corporation Heat resistant aerogel insulation composite, aerogel binder composition, and method for preparing same
US20050025952A1 (en) * 2002-05-15 2005-02-03 Cabot Corporation Heat resistant insulation composite, and method for preparing the same
JP2008506858A (ja) * 2004-07-16 2008-03-06 アドバンスド ファイバー テクノロジーズ （エーエフティー）トラスト スクリーン・シリンダの製造方法およびスクリーン・シリンダ
US8713798B2 (en) 2004-07-16 2014-05-06 Aikawa Fiber Technologies Trust Screen cylinder
US7856718B2 (en) * 2004-07-16 2010-12-28 Advanced Fiber Technologies (Aft Trust) Method of manufacturing a screen cylinder and a screen cylinder
US20110042300A1 (en) * 2004-07-16 2011-02-24 Advanced Fiber Technologies (Aft) Trust Screen cylinder
JP4662989B2 (ja) * 2004-07-16 2011-03-30 アドバンスド ファイバー テクノロジーズ （エーエフティー）トラスト スクリーン・シリンダの製造方法およびスクリーン・シリンダ
US20070251092A1 (en) * 2004-07-16 2007-11-01 Advanced Fiber Technologies (Aft) Trust Method of Mnaufacturing a Screen Cylinder and a Screen Cylinder
US9254586B2 (en) 2008-06-11 2016-02-09 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Process for producing a fuel tank with underride protector
US20110240389A1 (en) * 2010-03-31 2011-10-06 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Fuel tank
US8579062B2 (en) * 2010-03-31 2013-11-12 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Fuel tank
US20160009019A1 (en) * 2013-03-05 2016-01-14 Honda Motor Co., Ltd. Blow-molding mold
US9375870B2 (en) * 2013-03-05 2016-06-28 Honda Motor Co., Ltd. Blow-molding mold
US10160311B2 (en) 2013-03-29 2018-12-25 Plastic Omnium Advanced Innovation And Research Method for manufacturing a fuel tank or filling pipe and use thereof in a hybrid vehicle
CN105579271A (zh) * 2013-09-25 2016-05-11 本田技研工业株式会社 机动车用燃料箱
JP2016043564A (ja) * 2014-08-22 2016-04-04 株式会社Fts ブロー成形方法
US20170217075A1 (en) * 2014-09-29 2017-08-03 Plastic Omnium Advanced Innovation And Research Method for welding a heat shield during manufacturing of a vehicle component
US10596744B2 (en) * 2014-09-29 2020-03-24 Plastic Omnium Advanced Innovation And Research Method for welding a heat shield during manufacturing of a vehicle component
EP3233520B1 (fr) 2014-12-19 2021-02-24 Mubea Carbo Tech GmbH Structure de bouclier thermique pour une roue
WO2016168899A1 (fr) * 2015-04-24 2016-10-27 Carbon Revolution Pty Ltd Procédé de production d'un composite protégé thermiquement
US10759022B2 (en) 2015-04-24 2020-09-01 Carbon Revolution Limited Method of producing thermally protected composite

Also Published As

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DE69205065D1 (de) 1995-11-02
DE69205065T2 (de) 1996-02-29
US5308571A (en) 1994-05-03
EP0516290B1 (fr) 1995-09-27
EP0516290A1 (fr) 1992-12-02

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